US9815254B2 - Lightweight, high flow hose assembly and method of manufacture - Google Patents

Abstract

A hose assembly, preferably a garden hose assembly, including a fabric jacketed tube that is lightweight, durable and versatile. The tube is radially expandable when pressurized by a fluid, such as water, but does not increase in length. The two layer construction of the hose assembly allows for storage in relatively compact spaces, similar flow rates, approximately one-half the weight, and improved maneuverability when compared to conventional hose constructions. In one embodiment the jacket is formed around the tube in a continuous process that welds a fabric, preferably using hot air, into the jacket. The welded joint forms a region of jacket that is preferably about twice the thickness of the rest of the jacket. This thicker region results in a stiffer section of jacket that makes the hose more controllable and consistent in use.

Description

FIELD OF THE INVENTION

The present invention relates to a hose assembly, preferably a garden hose assembly, including a fabric jacketed tube, that is lightweight, durable and versatile. The tube is circumferentially or radially expandable within the jacket when pressurized by a fluid, such as water, but does not increase in length in a preferred embodiment. The two layer construction of the hose assembly allows for storage in relatively compact spaces, similar flow rates, approximately one-half the weight, and improved maneuverability when compared to conventional hose constructions. In one embodiment, the jacket is formed around the tube in a continuous process that welds a fabric, preferably using hot air, into the jacket. The welded joint forms a region of jacket that is preferably about twice the thickness of the rest of the jacket. This thicker region results in a stiffer section of jacket that makes the hose more controllable and consistent in use.

BACKGROUND OF THE INVENTION

Numerous different types or styles of garden hoses are known in the art and commercially available.

For example, traditionally conventional hoses are polymeric and can be reinforced, have a substantially fixed longitudinal length, and have relatively low radial expansion upon internal application of fluid pressure. Due to their construction, some conventional hoses can be relatively heavy and cumbersome to use and store.

More recently, garden hoses longitudinally expandable along their length multiple times as compared to the length of the hose in an unpressurized or contracted state have been introduced. In some embodiments such hoses have a construction that includes a jacket that surrounds an expandable fluid conveying tube. Longitudinally and radially expandable hoses are popular for a variety of reasons including, but not limited to, lightweight construction and ease of storage when not in use.

Longitudinally expandable hoses are commercially available from a number of sources. The hoses are also described in various patents and publications, see for example: U.S. Pat. Nos. 6,948,527; 7,549,448; 8,371,143; 8,776,836; 8,291,942; 8,479,776; 8,757,213; as well as U.S. Patent Application Publication Nos. 2014/0150889; and 2014/0130930.

A problem with some of the length expandable hoses is that they can kink, bulge, fail and/or exhibit leakage, at one or more points along their length, for example at a connection point to a coupler or fitting at the end of the hose, after a number of expansion and contraction cycles.

SUMMARY OF THE INVENTION

The problems described above and others are solved by the hose assemblies of the present invention which are relatively lightweight, as compared to the traditionally conventional hoses, durable, and versatile. In some embodiments, the hose assemblies provide a flow rate similar to a conventional garden hose at approximately one-half the weight. The hose assemblies also provide improved maneuverability due to their light weight, kink resistance in view of the non-bonded, two-layer jacket construction and ease of storage over a conventional hose.

According to one embodiment or objective of the present invention, a hose assembly is disclosed comprising a lightweight elastomeric inner tube surrounded by a fabric-like outer tube that serves as a jacket for the inner tube. This jacket also prevents the length of the product from changing at different pressure conditions. The length of the product is fixed by the outer jacket. The inner tube can expand along a radial axis of the tube when pressure at or above a minimum fluid pressure is applied to the inner tube. When the pressure falls below the minimum fluid pressure, the inner tube of the hose assembly will contract radially. The outer tube limits the radial expansion of the inner tube and does not allow any substantial longitudinal expansion of the hose assembly in one embodiment.

Still another embodiment or objective of the present invention is to provide a hose assembly including a fabric outer tube that is welded around the inner tube and includes a weld seam extending along a longitudinal axis of the hose assembly. The weld seam has a greater thickness, i.e. wall thickness, as compared to a wall thickness of the unwelded fabric.

Yet another embodiment or objective of the present invention is to provide a method for producing a hose assembly comprising a hot air welding or seaming process whereby the outer tube is formed via welding, preferably hot air welding, around the inner tube, preferably utilizing a continuous process. It is possible for the circumferential size of the outer tube to be varied in order to produce hose assemblies having different maximum internal diameters of the inner tube.

An additional embodiment or objective of the present invention is to provide a method for producing a hose assembly comprising the steps of obtaining a polymeric or synthetic fabric, heating lateral sides of the fabric at or above a melting temperature thereof and bonding the lateral sides together around an inner tube in order to form a weld. As the fabric is bonded along the length of the inner tube, the outer tube is formed having a weld seam along the longitudinal length of the hose assembly. Advantageously, the process for preparing the hose assembly of the present invention allows manufacture of an outer tube having a weld that is stronger than the original fabric has relatively low labor costs and also produces a construction having the inner tube inserted into the outer tube as part of the welding process.

An additional embodiment or objective of the present invention is to provide a hose assembly capable of resisting water pressures in the 400 psi range (pounds per square inch) 2758 kPa. Even though the hose is of a robust construction, the assembly is relatively light in weight, for example about 4 lbs per 50 feet (0.12 kg per meter) in one preferred embodiment.

In one aspect, a hose assembly is disclosed, comprising an inner tube comprising an elastomeric material, wherein the inner tube has a longitudinal length and a first circumference below a minimum expansion pressure, wherein the inner tube and is expandable to a larger, second circumference upon application of fluid pressure on an inner surface of the inner tube at or above the minimum expansion pressure; and an outer tube covering the inner tube, the outer tube having a longitudinal length and a weld seam along the longitudinal length of the outer tube, the weld seam comprising melted fabric. The inner tube and outer fabric covering are the same length in a preferred embodiment.

In another aspect a process for producing a hose assembly is disclosed, comprising the steps of obtaining an inner tube comprising an elastomeric material; obtaining a fabric having a first end, a second end a first side and a second side, the sides located between the ends; wrapping the fabric around the inner tube and abutting the first side and the second side of the fabric, and heating the fabric to melt and bond the first side to the second side along a length of the side thereby forming an outer tube having a weld seam along a longitudinal length of the hose assembly, wherein during formation of the outer tube a section of the inner tube is located inside the outer tube.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and other features and advantages will become apparent by reading the detailed description of the invention, taken together with the drawings, wherein:

FIG. 1 is a partial, cross-sectional, longitudinal side view of one embodiment of a hose assembly of the present invention in a circumferentially contracted position;

FIG. 2 is a partial, cross-sectional, longitudinal side view of one embodiment of a hose assembly of the present invention in a circumferentially expanded position; and

FIG. 3 is a partial, longitudinal side view of one embodiment of the hose assembly of the present invention particularly illustrating a weld seam of the outer tube produced by a hot air seaming method that encases an inner tube within the outer tube.

DETAILED DESCRIPTION OF THE INVENTION

In this specification, all numbers disclosed herein designate a set value, individually, in one embodiment, regardless of whether the word “about” or “approximate” or the like is used in connection therewith. In addition, when the term such as “about” or “approximate” is used in conjunction with a value, the numerical range may also vary, for example by 1%, 2%, 5%, or more in various other, independent, embodiments.

The hose assembly of the present invention includes a fabric jacketed inner tube, with the hose assembly being relatively light in weight, durable and versatile. The inner tube can expand circumferentially or radially to an expanded position or state in response to at least a minimum fluid pressure applied internally to the inner tube. The circumference of the fabric jacket controls radial expansion of the inner tube. The inner tube circumferentially or radially contracts when fluid pressure inside the tube falls below the minimum fluid pressure to a contracted or non-expanded position or state. In one embodiment, the outer tube jacket is formed around the inner tube in a continuous process that welds a fabric, preferably using hot air, into the jacket.

Referring now to the drawings wherein like reference numbers refer to like parts throughout the several views, ahose assembly10 is illustrated inFIGS. 1 and 2, whereinFIG. 1 illustrates the hose assembly in an out-of-service or contracted position andFIG. 2 an expanded position.Hose assembly10 includes aninlet14 and anoutlet16, withfluid passage12 being located therebetween. The hose assembly includes aninner tube20 that extends between and fitting or couplers, see for examplemale coupler60 andfemale coupler50. Theinner tube20 is self-expanding and self-contracting.Inner tube20 has aninner surface22 and anouter surface24, seeFIGS. 1-2, for example. When a fluid, such as water when the hose assembly is utilized as a garden hose, is introduced into theinner tube20 and exerts at least a minimum fluid pressure on aninner surface22, theinner tube20 expands, generally radially, from a first circumference to a larger, second circumference in an expanded position.Inner tube20 can be formed such that the second circumference provides the tubeinner surface22 with a desired inner diameter, for example about 0.5 inch (1.27 cm) or about 0.625 inch (1.59 cm). When fluid pressure decreases below the minimum fluid pressure, theinner tube20 relaxes or contracts radially, preferably back to the first circumference.

The thickness of theinner tube20 can vary depending upon the materials utilized to construct the same. In various embodiments, the wall thickness of the inner tube ranges generally from about 1.0 to about 2.0 mm, desirably from about 1.2 to about 1.8 mm, preferably from about 1.40 to about 1.65 mm, as measured in a radial direction in a contracted position.

Hose assembly10 also includes a jacket sheath orouter tube40 that is also connected between first and second couplers, see for examplemale couplers60 andfemale couplers50. In one embodiment, theouter tube40 is not connected or attached to theinner tube20 or an outerslip coating layer30, further described below, between the couplers. Stated in another manner, theouter tube40 is preferably unattached, unconnected, unbonded, and unsecured to either theinner tube20 orslip coating layer30, when present, along the entire length of theinner tube20 andslip coating layer30 between the first end and the second end of theouter tuber40, and thus thetube40 is able to move freely with respect to theinner tube20 and/or slipcoating layer30 when the hose assembly expands or contracts. In one embodiment, the circumferential or radial expansion ofinner tube20 is limited by the dimensions, i.e. maximum inner diameter or circumference ofouter tube40. Theouter tube40 is configured to protect theinner tube20 andslip coating layer30, when present, such as from cuts, friction, abrasion, puncture, over-expansion (bursting) or UV exposure.

In various embodiments theouter tube40 can be braided or woven into a fabric that is subsequently formed into the tube. Suitable materials include, but are not limited to, polyolefins, polyesters, and polyamides such as nylon. Polyester is preferred in some embodiments.Outer tube40 should be formed from a material that is pliable and strong enough to withstand a desired internal pressure that can be exerted byouter surface24 ofinner tube20. Thickness of theouter tube40 is dependent on yarn denier used. This will be dictated by desired internal pressure as mentioned above.

In an important aspect of the present invention, the hose assembly jacket orouter tube40 is formed around theinner tube20, preferably in a continuous process. In a preferred embodiment a hot air welding process is utilized. During the process, a piece of fabric having first and second ends and first and second sides located therebetween is formed into a tubular shape. A portion of the first side and the second side is heated to a temperature where the material, in particular polymer, that forms the fabric melts and the sides are bonded together, with the inner tube being present within or surrounded by the outer tube formed by the fabric. A weld46 is formed in the area where the fabric is heated and the sides are joined. As the fabric is joined along the length of the sides, the welded fabric forms a spine or weld seam48 extending longitudinally along the length of the fabric, comprising melted fabric. In a preferred embodiment, the weld seam has an overlap or weld width of 0.375 inch (9.5 mm)+/−0.0625 inch (+/−1.5 mm), generally measured perpendicular to the longitudinal length of the weld seam. In another embodiment, the variation is +/−3 mm. In one embodiment, the process that forms the welded seam is a continuous process that heats the fabric with hot air, with temperatures ranging between 550 and 750° C. and preferably between 600 and 700° C. The welding process also produces a weld seam having a wall thickness that is generally at least 50% greater, desirably at least 75% greater and preferably about 100% greater, i.e. two times greater, than the average thickness of the non-welded fabric of the outer tube.

In one embodiment, theinner tube20 is supplied from a reel or spool. In another embodiment, theinner tube20 is supplied directly from an upstream extrusion line. The inner tube enters a folding fixture which contains a series of guides and is combined with a flat, woven fabric. The fabric is supplied from a fabric source, such as a bulk container and straightened and tensioned as it enters the folding fixture. The folding fixture partially forms the fabric around the inner tube. The inner tube and fabric then enter a die which completes the forming process by shaping the fabric into a round, tubular shape. The tubular fabric profile and inner tube exit the die. At the exit of the die, a nozzle directs hot air between the overlapped fabric side surfaces. This hot air heats the fabric to or above its melting point just before the fabric and inner tube pass through a set of nip rollers which force the heated fabric surfaces against each other under pressure. A strong bond between the two fabric surfaces is formed at this point. The fabric and tube may be wound onto a reel for future assembly or cut to length and processed into a finished hose immediately. Hot air seaming devices are available from companies such as Miller Weldmaster of Navarre, Ohio.

Inner tube20 can be formed from any suitable elastic material. Suitable materials include, but are not limited to, rubbers including natural rubber, synthetic rubber and combinations thereof; and various thermoplastic elastomers including thermoplastic vulcanizates. Suitable thermoplastic elastomers include but are not limited to styrenic block copolymers, for example SEBS, SEEPS, and SBS; and SIS. In one embodiment the inner tube has a hardness that ranges from 20 to 60 Shore A, desirably from 25 to 60 Shore A, and preferably from 30 to 50 Shore A, as measured according to ASTM D-2240.

The inner tube compositions of the present invention may include additional additives including, but not limited to antioxidants, foam agent, pigments, heat stabilizers, UV absorber/stabilizer, processing aids, flow enhancing agents, nanoparticles, platelet fillers and non-platelet fillers.

In some embodiments of the present invention,slip coating layer30 is provided onouter surface24 ofinner tube20, seeFIGS. 1 and 2. In a preferred embodiment, theslip coating layer30 can be extruded onto or coextruded with theinner tube20 layer. Other application methods such as coating would also be acceptable so long as the slip coating performs its intended function.

Theslip coating layer30 can be a continuous or discontinuous layer or layers. In one preferred embodiment the slip coating layer is continuous, at least prior to a first expansion ofinner tube20 after the slip coating layer has been applied. Depending on the thickness of theslip coating layer30 relatively thin layers, after one or more expansions of theinner tube20, may exhibit cracking, splitting, crazing, fracturing or the like. Importantly though, such layers have still been found to be effective. That said, the initial thickness of theslip coating layer30 ranges generally from about 0.025 mm to about 0.51 mm, desirably from about 0.05 to about 0.25 and preferably from about 0.10 to about 020 mm, or about 0.15 mm measured in a radial direction.

As illustrated inFIGS. 1 and 2, theslip coating layer30 is located between theinner tube20 and the outer tube covering40. In a preferred embodiment, the slip coating layer is not directly connected to the outer tube covering40 between the first coupler and the second coupler, e.g.male coupler60 andfemale coupler50, such that the outer tube covering40 can slide or otherwise move in relation to theslip coating layer30 during expansion and contraction ofhose assembly10. In an expanded position, the outer surface of theslip coating layer30 is in contact with the inner surface of the outer tube covering40.

The slip coating layer comprises a lubricant, optionally incorporated into or blended with a carrier material.

In one embodiment, the lubricant is a siloxane polymer or copolymer, or a fluorinated polymer or a combination thereof. A siloxane polymer masterbatch is available from Dow-Corning as MB50321™ and from Wacker as Genioplast™. Fluorinated polymer is available from McLube as MAC 1080™ In some embodiments lubricant is present in the slip coating layer in an amount generally from about 1 to about 40 parts, desirably from about 2 to about 30 parts and preferably in an amount from about 3 to about 20 parts based on 100 total parts by weight of the slip coating layer. In other embodiments, the lubricant can be a liquid, semi-solid or solid material that serves to reduce friction between the inner tube and the outer tube. Non-limiting examples of other lubricants include, but are not limited to, oils such as silicone oil, waxes, polymers, including elastomers.

As described herein, in one embodiment the lubricant is mixed with a carrier material that aids in affixing the lubricant on an outer surface of the inner tube. Suitable materials include, but are not limited to, polyolefins, thermoplastic elastomers or a combination thereof. In one embodiment, the carrier material comprises a polyolefin and one or more of the thermoplastic elastomers utilized in the inner tube layer.

Along with the lubricant, the slip coating layer may also include additional additives including, but not limited to, antioxidants, foaming agents, pigments, heat stabilizers, UV absorber/stabilizer, processing aids, flow enhancing agents, nanoparticles, platelet fillers and non-platelet fillers.

Hose assembly10 includesmale coupler60 at a first end andfemale coupler50 at a second end. Themale coupler60 includes an external threadedsection62 and aninternal connector63 fixedly connected, such as by a press fit, tomain body66 ofmale coupler60.Connector63 includes astem64 initially having asmaller diameter portion63 that is connected to a larger diameter portion connected to the inner side of threadedsection62. Fluid passing throughmale coupler60 passes throughinternal connector63, generally throughaperture67 instem64 and out through the end ofconnector63 within threadedsection62. In one embodiment, thestem64 is inserted into theinner tube20. A portion of the outer tube covering40 is also located betweenstem64,inner tube20 and theferrule68 ofmale coupler60.Inner tube20 andouter tube40 are operatively connected and secured tomale coupler60 by expansion of thestem64 outwardly towardsferrule68. In other embodiments the ferrule can be crimped towards a relatively rigid stem in order to capture the inner tube and outer tube therebetween, securing the tubes to themale coupler60. Other attachment mechanisms could also be utilized.

Thefemale coupler50 includes amain body56 having an internal threadedsection52 that is operatively and rotatably connected to a second end ofhose assembly10 opposite the end containingmale coupler60. Threadedsection52 is constructed such that it can be operatively connected to a male fitting of a spigot, faucet, or other similar valve control device.

Theinternal connector53 offemale coupler50 is rotatable in relation tomain body56 such that the main body is also rotatable in relation to theinner tube20 andouter tube40 which are operatively connected or fixed to stem54. A ferrule51 is placed onto the jacket orouter tube40 andinner tube20. The ferrule51,inner tube20, and fabric jacketouter tube40 are then fitted ontostem63.Stem63 is then expanded to secure the hose to the fitting. As mentioned above with respect to the male coupler, alternative constructions can be utilized to secure theinner tube20 andouter tube40 to thefemale coupler50. As illustrated inFIG. 1,connector53 includes areceptacle55 in the form of a cavity, recess, or the like that accommodatesflange57 of themain body56. In the embodiment illustrated, theflange57 is a ring-like feature projecting inwardly from themain body56 and includes an end that is located withinreceptacle55. The flange structure allows themain body56 to spin or rotate aroundconnector53. Awasher59 is located at the base of threadedsection52 in order to provide a desired seal between the female coupler and a device that is threadably connectable to threadedsection52.

Alternatively, other common couplers, fittings or hose end connections can be utilized and include, but are not limited, crimped (external), barbed, or clamped couplings made from plastics, metals, or combinations thereof.

Thehose assembly10 is illustrated in a contracted position with respect to circumference inFIG. 1. In this position, the elasticinner tube20 is in a contracted or relaxed state with no internal force being applied to theinner surface22 sufficient to expand or stretchinner tube20. Depending on the material utilized for outer tube covering40, space may exist between the same and theslip coating layer30, if present, and/orinner tube20 when the hose assembly is in a contracted position.

The fluid pressure withininner tube20 can be increased for example by preventing fluid from being expelled throughoutlet16, such as with the use of an associated nozzle or the like (not shown) and introducing fluid under pressure into theinlet14 ofhose assembly10. Once a minimum threshold pressure is met or exceeded, theinner tube20 undergoes circumferential expansion. Expansion ofinner tube20 results in a decrease in wall thickness of the inner tube and an increase in the circumference or diameter of the inner tube. Thus, a higher volume of fluid can be present ininner tube20 in the expanded position as compared to the volume of fluid that can be present in a contracted position, below the minimum fluid pressure.

Depending upon the construction of the outer tube covering40, in the expanded position, the covering may exhibit a relatively smooth, cylindrical character along its length, seeFIG. 2 for example.

Standard water pressure for water exiting a spigot from a municipal water system is about 45 to about 75 psi (310.3 to 517.1 kPa) and typically about 60 psi, 413.7 kPa. Such pressure is sufficiently above a minimum fluid pressure required for the hose to expand. The minimum fluid pressure that causes theinner tube20 ofhose assembly10 to expand will vary depending on the construction or composition thereof. When a nozzle or other flow restricting device is connected to themale coupler60 ofhose assembly10, with the female coupler70 being operatively connected to a spigot, theinner tube20 will expand when the spigot valve is opened or turned on as water under pressure will flow into the hose. If the nozzle prevents the flow of fluid through the inner tube, the pressure inside the inner tube will achieve substantially the same pressure as that coming from the fluid pressure source, such as 60 psi (289.6 kPa) in the case of a standard municipal water supply. When fluid is released from theoutlet16 ofhose assembly10 through a suitable nozzle, the pressure inside theinner tube20 is reduced. The hose assembly will remain in an expanded position when the fluid pressure remains above the minimum fluid pressure. In a preferred embodiment, the couplers are full flow fittings. They are not designed to create back pressure within the hose.

The hose assemblies formed by the present invention are relatively lightweight, when compared to a conventional garden hose. Hose assemblies of the present invention are capable of withstanding water pressures in the 400 psi (2758 kPa) range while still being relatively light. For example, a 50 foot hose assembly of the present invention including couplers or end fittings can weigh about 4 lbs. with inner and outer tubes that are about 50 feet in length. The hose assemblies are very flexible and can be easily stored in compact spaces that a conventional garden hose would not fit, such as a bucket or similar container. The hot air seaming or welding process according to the present invention allows manufacture of a hose assembly utilizing less labor input, while having the inner tube automatically inserted into the outer tube which is formed therearound as part of the welding process.

The hose assemblies of the present invention are particularly suitable for cold water applications.

Due to the flexibility and versatility of the hose assemblies, one can utilize a fastener system such as a hook and loop fastener system, for example VELCRO® to harness the hose assembly when not in use. A fastener strap can be attached to one end of the hose by threading an end of a fastener through a female eyelet thereof such that the fastener can be permanently affixed to the hose assembly.

The hose assemblies of the present invention can also be formed from FDA listed ingredients for non-food contact applications, such as RV and marine drinking water service.

EXAMPLES

Burst Testing

One embodiment of a garden hose assembly according to the present invention including a fabric outer tube having a weld seam formed from a hot air welding process, the weld seam extending along a longitudinal length of the outer tube, the weld seam comprising melted fabric, was pressurized to failure. The peak pressure was recorded. This product was comparable to heavy duty, conventional constructions.

Elevated Temperature Burst

Garden hose assemblies as described in the example above were burst tested at 120° F. to determine how they would perform in hot conditions. This inventive construction did not lose as much burst strength at high temperatures compared to existing constructions.

Puncture Resistance

A pointed penetrator was forced against a pressurized hose assembly as described above. The peak force required to form a leak was recorded. This construction was comparable to heavy duty, conventional constructions.

While in accordance with the patent statutes the best mode and preferred embodiment have been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.

Claims (20)

What is claimed is:

1. A hose assembly, comprising:

an inner tube comprising an elastomeric material, wherein the inner tube has a longitudinal length and a first circumference below a minimum expansion pressure, wherein the inner tube is expandable to a larger, second circumference upon application of fluid pressure on an inner surface of the inner tube at or above the minimum expansion pressure; and

an outer tube covering the inner tube, the outer tube having a longitudinal length and a weld seam along the longitudinal length of the outer tube, the weld seam comprising melted fabric, wherein the hose assembly further includes a male coupler connected to first ends of the inner tube and the outer tube and a female coupler connected to second ends of the inner tube and the outer tube, and wherein the outer tube is not connected or attached to the inner tube between the male coupler and the female coupler.

2. The hose assembly according toclaim 1, wherein the outer tube has a first end and a second end and two sides between ends, wherein the two sides are bonded at the weld seam, and wherein the outer tube has a fixed longitudinal length.

3. The hose assembly according toclaim 1, wherein the outer tube has an inner surface with a circumference and the second circumference of the inner tube is less than or equal to the outer tube inner surface circumference.

4. The hose assembly according toclaim 1, wherein a slip coating layer comprising a lubricant is present on an outer surface of the inner tube.

5. The hose assembly according toclaim 1, wherein the weld seam has a weld width of 9.5 mm+/−3.0 mm, and wherein the weld seam has a weld thickness that is at least 50% greater than a thickness of the fabric of the outer tube in a non-weld seam section.

6. The hose assembly according toclaim 5, wherein the weld seam weld width is 9.5 mm+/−1.50 mm, and wherein the weld thickness is at least 75% greater than the thickness of the fabric of the outer tube in the non-weld seam section.

7. The hose assembly according toclaim 6, wherein the weld seam weld thickness is at least 100% greater than the thickness of the fabric of the outer tube in the non-weld seam section.

8. A process for producing the hose assembly according toclaim 1, comprising:

obtaining the inner tube comprising the elastomeric material;

obtaining a fabric having a first end, a second end, a first side and a second side, the sides located between the ends;

wrapping the fabric around the inner tube and abutting the first side and the second side of the fabric, and

heating the fabric to melt and bond the first side to the second side along a length of the sides thereby forming the outer tube having the weld seam along the longitudinal length of the hose assembly, wherein during formation of the outer tube a section of the inner tube is located inside the outer tube.

9. The process according toclaim 8, further including the step of overlapping the first side and the second side of the fabric 9.5 mm+/−3.0 mm.

10. The process according toclaim 9, further including the step of overlapping the first side and the second side of the fabric 9.5 mm+/−1.5 mm.

11. The process according toclaim 9, wherein the heating step comprises heating the fabric with hot air at a temperature between 550° C. and 750° C.

12. The process according toclaim 11, further including the step of partially forming the fabric around the inner tube with a folding fixture and shaping the fabric into a round, tubular profile using a die.

13. The process according toclaim 12, further including a step of passing the inner tube and outer tube through a set of rollers which force the heated fabric surfaces against each other under pressure after the heating step.

14. The process according toclaim 8, wherein the heating step comprises heating the fabric with hot air at a temperature between 550° C. and 750° C.

15. The process according toclaim 14, further including the step of partially forming the fabric around the inner tube with a folding fixture and shaping the fabric into a round, tubular profile using a die.

16. The process according toclaim 15, further including a step of passing the inner tube and outer tube through a set of rollers which force the heated fabric surfaces against each other under pressure after the heating step.

17. A hose assembly, comprising:

an inner tube comprising an elastomeric material, wherein the inner tube has a longitudinal length and a first circumference below a minimum expansion pressure, wherein the inner tube is expandable to a larger, second circumference upon application of fluid pressure on an inner surface of the inner tube at or above the minimum expansion pressure; and

an outer tube covering the inner tube, the outer tube having a longitudinal length and a weld seam along the longitudinal length of the outer tube, the weld seam consisting of melted fabric, wherein the hose assembly further includes a male coupler connected to first ends of the inner tube and the outer tube and a female coupler connected to second ends of the inner tube and the outer tube, and wherein the outer tube is not connected or attached to the inner tube between the male coupler and the female coupler.

18. The hose assembly according toclaim 17, wherein the outer tube has a first end and a second end and two sides between ends, wherein the two sides are bonded at the weld seam, and wherein the outer tube has a fixed longitudinal length.

19. The hose assembly according toclaim 18, wherein the weld seam has a weld width of 9.5 mm+/−3.0 mm, and wherein the weld seam has a weld thickness that is at least 50% greater than a thickness of the fabric of the outer tube in a non-weld seam section.

20. The hose assembly according toclaim 19, wherein the weld seam weld width is 9.5 mm+/−1.50 mm, and wherein the weld thickness is at least 75% greater than the thickness of the fabric of the outer tube in the non-weld seam section.

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